Composition and Method to Form a Composite Core Material

ABSTRACT

A composition and method to form a composite core material for use as a panel, molded product, sheet, or reinforcing material. The composition generally includes a microsphere discontinuous portion disposed in a continuous encapsulating portion, such as an encapsulating resin. Final products made with the composition may also comprise a mesh assembly on one or both sides of a sheet or panel, and may comprise a scored panel or sheet such that a plurality of reinforcing blocks or sections are formed which allow the cured product to conform to, and reinforce, irregular shapes and surfaces.

CROSS REFERENCE TO RELATED APPLICATIONS

I hereby claim benefit under Title 35, United States Code, Section119(e) of U.S. provisional patent application Ser. No. 62/599,442 filedDec. 15, 2017. The 62/599,442 application is currently pending. The62/599,442 application is hereby incorporated by reference into thisapplication.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable to this application.

BACKGROUND Field

Example embodiments in general relate to a composition and method toform a composite core material, and for testing the compressive strengthof the material.

Related Art

Any discussion of the related art throughout the specification should inno way be considered as an admission that such related art is widelyknown or forms part of common general knowledge in the field.

A composite material (also called a composition material or shortened tocomposite) is a material made from two or more constituent materialswith significantly different physical or chemical properties that, whencombined, produce a material with characteristics different from theindividual components. The new material may be preferred for manyreasons: common examples include materials which are stronger, lighter,or less expensive when compared to traditional materials.

Transportation, construction and aerospace are the largest marketsegments within the composites industry recently, representing 62percent of its total value. Development of low-cost, light weight, andhigh-strength composite material to be used in those industries isimportant.

SUMMARY

An example embodiment is directed to a composition and method to form acomposite core material. The composition and method to form a compositecore material includes solid or hollow microspheres mixed with anencapsulating material, so that, when hardened, a lightweight structure,such as a panel, may be formed that retains the high strength of theencapsulating material. The encapsulating material may comprise a resin,such as a polyester resin, a vinyl ester resin, or a fire retardantresin, or any combination of such resins.

There has thus been outlined, rather broadly, some of the embodiments ofthe composition and method to form a composite core material in orderthat the detailed description thereof may be better understood, and inorder that the present contribution to the art may be betterappreciated. There are additional embodiments of the composition andmethod to form a composite core material that will be describedhereinafter and that will form the subject matter of the claims appendedhereto. In this respect, before explaining at least one embodiment ofthe composition and method to form a composite core material in detail,it is to be understood that the composition and method to form acomposite core material is not limited in its application to the detailsof construction or to the arrangements of the components set forth inthe following description or illustrated in the drawings. Thecomposition and method to form a composite core material is capable ofother embodiments and of being practiced and carried out in variousways. Also, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of the description and should not beregarded as limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments will become more fully understood from the detaileddescription given herein below and the accompanying drawings, whereinlike elements are represented by like reference characters, which aregiven by way of illustration only and thus are not limitative of theexample embodiments herein.

FIG. 1 is a flow chart for forming a composite core material inaccordance with an example embodiment.

FIG. 2 is a flow chart for forming a composite product with a compositecore material in accordance with an example embodiment.

FIG. 3 is a perspective view of a composite product in accordance withan example embodiment.

FIG. 4 is a perspective view of the composite core material inaccordance with an example embodiment.

FIG. 5 is an end view of a scored composite core material in accordancewith an example embodiment.

FIG. 6 is a perspective view of a mold body usable for making acomposite panel in accordance with an example embodiment.

FIG. 7 is a perspective view of a mold body with a mesh assembly inplace, usable for making a composite panel in accordance with an exampleembodiment.

FIG. 8 is a perspective view of a mold top with a reinforcing layer inplace, usable for making a composite panel in accordance with an exampleembodiment.

FIG. 9 is a perspective view of a mold bottom, mold body, and mold topin place, usable for making a composite panel in accordance with anexample embodiment.

FIG. 10 is a perspective view of an assembled, closed mold body showingtubing for infusing composite matrix material into the mold, usable formaking a composite panel in accordance with an example embodiment.

FIG. 11 is a sectional view of a composite panel in accordance with anexample embodiment.

DETAILED DESCRIPTION A. Overview.

An example composition and method to form a composite core material, andproducts made from the material generally comprises compositions of acomposite core material, methods to form such compositions, methods toform a composite product with such compositions, and methods to test thecompressive strength of such compositions.

B. Microspheres.

As shown in the Figures and described in example embodiments,microspheres 16 may be encapsulated in a resin material to createsheets, panels, or molded structures, for example. Solid or hollowplastic microspheres 16 are small spherical plastic, ceramic or glass,etc. particles. The microspheres typically consist of a polymer shellencapsulating a gas (if they are hollow). When the gas inside the shellis heated, it increases its pressure and the thermoplastic shellsoftens, resulting in a dramatic increase in the volume of themicrospheres 16. In certain embodiments, when fully expanded, the volumeof the microspheres increases more than about 40 times. Glassmicrospheres 16 are microscopic spheres of glass manufactured for a widevariety of uses in research, medicine, consumer goods and variousindustries. Glass microspheres 16 are usually between 1 and 1000micrometers in diameter, although the sizes can range from 100nanometers to 5 millimeters in diameter. Hollow or solid glassmicrospheres, sometimes termed microballoons or glass bubbles, havediameters ranging from 10 to 300 micrometers. In example embodiments,the microspheres 16 disposed in an encapsulating material, such asresin, may be either hollow or solid.

Solid microspheres are known and usable to make lightweight and strongcomposite panels or other structures, as is also true of hollowmicrospheres. In certain embodiments, glass or ceramic spheres may beused to form the microsphere discontinuous portions of products. Someglass spheres comprise soda lime borosilicate glass and syntheticamorphous crystalline-free silica. In some example embodiments,microspheres are made of acrylic and PVC.

C. Encapsulating Resin.

In example embodiments, a composite core material 12 is made byintroducing microspheres 16 into an encapsulating resin mixture 15,which may be comprised of resin and other materials, and then allowingthe resin mixture to cure to form panels, scored sheets, or molded partsexhibiting the lightweight, high-strength, and insulating propertiesthat are useful in making parts for the transportation and otherindustries.

In some example embodiments, a continuous encapsulating resin 15 is apolymerized product of polyester resins having a structure of:

wherein n is from about 3 to about 6. This is just one example of a fireretardant resin 15 and is not meant to be limiting as other fireretardant resins may be used.

In other embodiments, the continuous encapsulating resin 15 is apolymerized product of vinyl ester resins having a structure of:

wherein n is 1 to about 2, where R₁ is hydrogen or alkyl, R₂ is hydrogenor alkyl, R₃ is hydrogen or alkyl, R₄ is hydrogen or alkyl.

In yet other embodiments, the continuous encapsulating resin 15 is apolymerized product of a combination of the polyester resins and thevinyl ester resins. The weight percentage of the polyester resin rangesfrom about 5% to about 95%, e.g., 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%,45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% or 95%. The weightpercentage of the vinyl ester resin ranges from about 95% to about 5%,e.g., 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%,30%, 25%, 20%, 15%, 10%, or 5%.

In some example embodiments, the composite core material also comprisesa blowing agent, or is formed through the use of a blowing agent. Ablowing agent can be a substance which is capable of producing acellular structure via a foaming process in a variety of materials thatundergo hardening or phase transition, such as polymers, plastics, andmetals. They are typically applied when the blown material is in aliquid stage. The cellular structure in a matrix reduces density,increasing thermal and acoustic insulation, while increasing relativestiffness of the original polymer. In some embodiments, the blowingagent may be a chemical blowing agent. In other embodiments, the blowingagent may be a physical blowing agent. In yet other embodiments, theblowing agent can be a combination of a chemical and physical blowingagent.

In another example embodiment, the composite core material 12 comprisesglass fibers.

The weight percentages of the microspheres 16 that make up adiscontinuous portion, and the continuous encapsulating resin mixture 15in the composite core material 12 can vary. In some embodiments, thecomposite core material 12 comprises about 1% to about 10% by weight ofthe microsphere discontinuous portion and about 90% to about 99% byweight the continuous encapsulating resin 15. In other embodiments, thecomposite core material 12 further comprises about 1-2% by weight of theblowing agent. In some embodiments, the composite core materialcomprises about 1-10% by weight of microspheres. In certain embodiments,the composite core material has a density of 0.25 to about 3.00lbs./ft³. The thickness of the composite core products may typicallyrange from about ⅛ inches to about 4 inches, although other thicknessesare possible as well.

D. Making the Composite Core Material and Product.

FIG. 1 summarizes an example method for making the composite corematerial 12. Referring to FIG. 1, in step 100, microspheres 16, anencapsulating prepolymer, a polymerization catalyst, and/or a blowingagent are provided. In some embodiments, polyester resins 15 are used.In other embodiments, vinyl ester resins 15 are used. In yet otherembodiments, styrene-based resins 15 are used. In yet other embodiments,a mixture of polyester and vinyl ester resins are used. In yet otherembodiments, fire retardant resins 15 are used. In some embodiments, apolymerization catalyst is 2-Butanone peroxide, having a structure of

2-Butanone peroxide has a molecular weight of about 210.22 and a densityof about 1.053 g/ml at 20° C. In other embodiments, any catalyst knownto a person in the art that can facilitate the polymerization of theencapsulating resin to encapsulate the discontinuous hollow or solidmicrosphere portions can be employed.

In step 110, all the materials provided in step 100 are mixed to form afirst mixture comprising microspheres, the encapsulating prepolymer, andthe polymerization catalyst. In certain embodiments, the polymerizationcatalyst has a concentration of about 1% to 2% by weight in a secondmixture of the encapsulating prepolymer and the polymerization catalyst.The weight percentage of the polymerization catalyst can be about 1%,1.25%, 1.5%, 1.75%, 2% or any other weight percentage that ranges fromabout 1% to about 2%.

In step 120, the first mixture comprising microspheres, an encapsulatingprepolymer, and a polymerization catalyst is poured onto a moving belt.In other embodiments, the first mixture may be poured into a mold 20(such as a closed mold), which contains a mesh assembly 14 orreinforcing material inside the mold, for example, in or near the bottomof the mold. The mesh assembly 14 may comprise a layer of fiberglassscrim, woven roving, or other reinforcing materials.

In certain embodiments, a moving belt is heated to facilitate thepolymerization of the encapsulating prepolymer. In certain embodiments,the mesh assembly 14 lays on top of the moving belt and the firstmixture is spread evenly over the mesh assembly.

In some embodiments, the mesh assembly has a width of 20 inches to 60inches. In other embodiments, the mesh assembly has a width of 24inches. In other example embodiments, the mesh assembly is a fiberglassmesh assembly, comprising fiberglass scrim. In yet other embodiments,other suitable materials known to a person skilled in the art can beused to make the mesh assembly.

In step 130, when the first mixture is disposed onto a moving belt, thefirst mixture is spread evenly over the mesh assembly 14. In someexample embodiments, a second mesh assembly 14 may be placed over themixture after it is applied, so that the cured composite core material12 will form a sheet or panel 10 with the cured composite core material12 substantially between two layers of mesh 14 near each flat surface,as shown in FIG. 11. When the first mixture is cured, the encapsulatingprepolymer is polymerized to form a sheet of composite core material 12comprising microspheres 16, comprising discontinuous portions disposedin a continuous encapsulating resin 15. In certain example embodiments,the sheet of composite core material may have a thickness of about 0.125inches to about 4 inches.

As discussed above, in addition to a moving belt, the panels 10 may alsobe created in a closed mold 20, such as the mold shown in FIG. 6. Themold comprises a mold body 22 that rests on a mold bottom 21. The moldbody 22 may be made of silicone or similar material to aid in removingthe cured panels from the mold, since many matrix materials will notadhere to silicone. Initially, a mesh assembly or reinforcing layer 14,such as fiberglass scrim, is installed in the portion of the mold inwhich the panel will be formed, as shown in FIG. 7.

As is known, a mesh assembly 14 adds strength to composite panels, aswith many composite construction techniques where a matrix materialsurrounds and encapsulates a reinforcing material.

If desired, another mesh assembly 14 may be installed on a mold top 25,which may be a glass top to allow users to view the process and ensurequality. Alternatively, the second mesh assembly 14 may be omitted,which would be the case if a panel 10 is to be scored for reinforcingirregular surfaces or components as described herein. FIG. 9 illustratesan example embodiment of a fiberglass scrim mesh assembly installed on amold top 25 prior to placement on the mold body 22. Next, the mold top25 is placed on the mold body 22 with the other reinforcing layer 14, ifused, positioned as needed to form a panel 10.

As shown in FIG. 10, when the composite matrix material 12 is introducedinto the mold (by way of non-limiting example, infused into the mold bya supply tube 26 coupled to infusion port 23), it flows into the mold,and may be aided in flow by a vacuum tube connected to vacuum port 24 atthe end of the mold body opposite the infusion port 23.

Thus, the uncured composite matrix material 12 can flow into the mold 20to all the spaces/voids not occupied by the mold. The composite matrixmaterial 12 will later cure to form a panel or sheet 10, or other moldedpart, as shown in the example embodiment in FIG. 3. When panels 10 areformed as shown in FIG. 3 (although other shapes and configurations arepossible), the outer surfaces of the panel 10 may be substantiallycoplanar.

Once the mold is filled with composite matrix material 12, the infusionor other addition of composite material is stopped and the material isallowed to cure due to elevated pressure, temperature, moisture, time,chemical reaction, etc.

If desired for an improved, high-quality finish, or for additionalenvironmental protection, an optional gel coat layer 17 can be appliedto one or both exterior surfaces of the panel 10, as shown in FIG. 3.

When the first composite mixture 12 is disposed into a mold 20 with amesh assembly 14 inside the mold, the first mixture is cured so that theencapsulating prepolymer is polymerized to form a panel, sheet, orblock, or molded part of composite core material 12 according to theshape of the mold. Such a molded composite part may also comprise asecond mesh assembly 14, placed or installed near a surface or side ofthe mold opposite the first mesh assembly 14, resulting in a panel orblock with a mesh assembly 14 near each major surface 18, 19, of thefinished product, as shown in FIG. 11. For example, if a flat,rectangular panel (e.g., shaped like a door) is formed in a mold, thefinished product may have mesh reinforcement layers or assemblies 14near one or two major flat surfaces 18 and 19 of the panel. As alsoshown in FIG. 11, the final product may have an optional gel coat 17 ifdesired for a finished, high-gloss surface. Such a gel coat can beapplied to either or both surfaces of a panel or sheet.

Further, in step 140, a decision is made as to whether the sheet of thecomposite core material needs to be scored into a plurality ofreinforcing blocks. In certain embodiments, smaller blocks of compositecore materials are warranted.

In step 150, the sheet 10 of the composite core material 12 may bescored into a plurality of reinforcing blocks, which may in turn be heldtogether by a mesh assembly 14 on a side opposite the scoring, as shownin FIGS. 4 and 5. As shown, a mesh assembly 14 is only formed on oneside of the sheet or panel 10. In FIGS. 4 and 5, the mesh assembly 14 isonly on or near surface 19, while surface 18 has no mesh assembly, sothat it can be scored into reinforcing blocks or sections as shown.

In certain example embodiments, each reinforcing block has a width ofabout 0.5 inches to about 4 inches and a length of about 0.5 inches toabout 4 inches. In addition, in step 160, the sheet of the compositecore material may be cut into a plurality of pieces with any desirablelength. In other embodiments, the sheet of composite core material ismaintained in a solid sheet without scoring in step 152. For convenienceof transportation, the sheet of composite core material can be cut intoa smaller sheet of 48 inches wide by 48 inches long, 48 inches wide by96 inches long, or any other width and length according to differentrequirements.

FIG. 2 summarizes an example method for utilizing the composite corematerial that is described below in certain embodiments in manufacturingappliances, machines, automobiles, and etc. Referring to FIG. 2, in step200, composite core materials formed in step 130 (FIG. 1) and shaped instep 130 or step 160 (FIG. 1) are provided.

In step 210, a mold of appliances, machines, automobiles, or etc. isprovided. For example, if a user would like to build a bathtubincorporating the composite core materials, the user would start with abathtub mold, i.e., a hollow form or matric for a particular shape of abathtub. If a user would like to build a truck bed utilizing thecomposite core materials, the user would first supply a truck bed mold,i.e., a hollow form or matric for a particular shape of a truck bed.

After selecting a particular mold, a first layer of gel coat 17 with apolymerization catalyst at a thickness of about 15 mils is optionallyapplied to the mold in step 220. If a gel coat is not applied, afterselecting a mold of a particular shape, a layer of laminate may beapplied. As described herein, “mil” is defined as a unit of length equalto about 1/1000 inch used especially in measuring thickness (as ofplastic films). The thickness of the gel coat is not limiting. Accordingto the type of mold selected and strength requirement of the finalproduct, the thickness of the gel coat applied varies accordingly. As aperson skilled in the art would appreciate, a gel coat is a materialused to provide a high-quality finish on a visible surface of afiber-reinforced composite. The most common gel coats are based on epoxyor unsaturated polyester resin chemistry.

Gel coats are modified resins which are applied to molds in the liquidstate. They are cured to form crosslinked polymers and are subsequentlybacked with composite polymer matrices, often mixtures of polyesterresin and fiberglass or epoxy resin with glass. The manufacturedcomponent, when sufficiently cured and removed from the mold, presentsthe gel-coated surface. In certain embodiments, this is pigmented toprovide a colored, glossy surface which improves the aestheticappearance of the article, such as a counter made with cultured marble.

In some embodiments, the first layer of gel coat is sprayed from aspraying apparatus onto the side of the selected mold from step 210. Inother embodiments, the first layer of gel coat is brushed onto theselected mold from step 210. Other applying methods know to a personskilled in the art can be used herein.

In certain embodiments, the polymerization catalyst has a concentrationof about 1% to about 2.5% by weight in the mixture of the gel coat andthe polymerization catalyst. The weight percentage of the polymerizationcatalyst can be about 1%, 1.25%, 1.5%, 1.75%, 2%, 2.25%, 2.5% or anyother weight percentage that ranges from about 1% to about 2.5%. In step220, the first gel coat is cured on the side of the mold at atemperature of about 100° C. for about 5 minutes. The particulartemperature and the length of time disclosed herein are not limiting,with various different types of gel coat applied, the particulartemperature and the length of the time for curing vary accordingly.

Once the gel coat is completely solidified, a first coat of laminatecomprising fibers, resins, and a polymerization catalyst may be applied.In certain embodiments, the fibers are selected from the groupconsisting of fiberglass, carbon fiber, and aramid fibers, and anycombinations thereof. In certain embodiments, the resins are selectedfrom the group consisting of polyester resins, vinyl ester resins, epoxyresins, and any combinations thereof.

In certain embodiments, the weight percentage of fibers ranges fromabout 10% to about 40% and the weight percentage of resins ranges fromabout 10% to about 70%. In certain embodiments, the polymerizationcatalyst has a concentration of about 1% to about 2.5% by weight in themixture of the encapsulating prepolymer and the polymerization catalyst.The weight percentage of the polymerization catalyst can be about 1%,1.25%, 1.5%, 1.75%, 2%, 2.25%, 2.50% or any other weight percentage thatranges from about 1% to about 2.5%.

In other embodiments, the laminate comprises calcium sulfate and/orhydrates thereof, an encapsulating prepolymer, a polymerizationcatalyst, and a plurality of fiberglass pieces. In certain embodiments,the third mixture comprises about 40% to 65% of calcium sulfate and/orhydrates thereof, about 60% to 35% of the encapsulating prepolymer, andabout 10% to 40% of the plurality of fiberglass pieces. In certainembodiments, the polymerization catalyst has a concentration of about 1%to about 2.5% by weight in the mixture of the encapsulating prepolymerand the polymerization catalyst. The weight percentage of thepolymerization catalyst can be about 1%, 1.25%, 1.5%, 1.75%, 2%, 2.25%,or any other weight percentage that ranges from about 1% to about 2.5%.

In step 230, the gel coat is dried without completely curing it. Becausethe first layer of gel coat is not completely cured but dried, the firstlayer of gel coat is still sticky to the touch. When applying the secondlayer of laminate in step 240, the second layer of laminate does notleak through the dried first layer of gel coat. When a gel coat is notapplied, a coat of laminate is directly applied to the mold provided instep 210.

In certain embodiments, the second layer of laminate is applied at athickness of about 50 to 250 mils, although the thickness of thelaminate layer is not limiting and other thicknesses are possible.According to the type of mold selected and strength requirement of thefinal product, the thickness of the laminate layer applied variesaccordingly. Further, to ensure even application of the laminate layer,a suitable appliance may be used to roll out any possible bubblespresented in the laminate layer.

In step 250, without solidifying the laminate layer in step 240,applying a plurality of pieces of the composite core materials from step160 to the uncured laminate layer. Depends on different types of molds,sheets of the composite core materials or different shapes of thecomposite core materials from step 130 can applied to the uncuredlaminate layer. However, the thickness of the composite core material isnot limiting. According to the type of mold selected and strengthrequirement of the final product, the thickness of the composite corematerial applied varies accordingly.

After applying pieces of the composite core material, another layer ofthe laminate is applied to pieces of composite core material in step260. This layer of laminate has the same composition as the laminatelayer described in step 240. In certain embodiments, the thickness ofthe laminate layer in step 260 is about 50 to about 250 mil. Similarly,the thickness of the laminate layer is not limiting. According to thetype of mold selected and strength requirement of the final product, thethickness of the laminate layer applied varies accordingly. After curingthe second layer of laminate in step 260, a composite productincorporating the composite core materials is formed in step 270. Theformed composite product encloses the mold selected in step 210.

Further, in step 280, a decision is made whether a compressive strengthtesting is needed on the piece of the composite material. If yes, step280 transitions to step 284, one or more compressive strength tests willbe carried out. If no, step 280 transitions to step 282. As describedherein, compressive strength or compression strength is the capacity ofa material or structure to withstand compressive loads, as opposed totensile strength, which withstands loads tending to elongate. In otherwords, compressive strength resists compression (being pushed together),whereas tensile strength resists tension (being pulled apart). In thestudy of strength of materials, tensile strength, compressive strength,and shear strength can be analyzed independently.

Example 1

A resin absorption test was performed on the composite material formedin step 250. As shown in Table 1 below,

TABLE 1 Resin absorption for the composite material formed in step 250vs. Balsa core. Current disclosed composite core Balsa Core % Resinabsorption by 1.6% 75.9% weight Calculated dry density 0.78 0.14 g/ccCalculated resin- 0.79 0.29 saturated density g/cc

E. Operation of Preferred Embodiment.

As discussed above, example embodiments disclosed may be used to createlightweight, very strong panels or sheets that are highly resistant torot, moisture, mold, etc. Such panels or sheets also provide goodinsulation and noise reduction, which is enhanced due to themicrospheres encapsulated in the resin mixture. Microspheres, such ashollow microspheres, have good sound and thermal insulation propertiesdue to their hollow structure. The example embodiments disclosed hereinmay be used to create substantially rigid flat or curved panels orsheets. For example, flat and curved panels or molded parts can be madeusing the microsphere mixture with a mesh assembly, such as fiberglassscrim, on the major surfaces of the parts. Such panels or parts aretypically stronger than wood, for example, and have good rigidity andenvironmental characteristics as well, as discussed above.

The composite core material, such as a scored panel (of virtually anysize and shape) may be used for reinforcement where conformance to anirregular surface or parts is desired. Obviously, a flat composite panelcannot be used advantageously to reinforce a curved surface, or an areawith a pipe or other structures. Many such areas might be found, forexample, in interior areas and spaces of boats, aircraft, RVs, etc.Panels 10 made according to the example methods described here can bescored on a side opposite of the mesh assembly, (see FIG. 4) to a depthnear the mesh assembly 14. In such an example embodiment, the mesh layerwill serve to hold the scored blocks together. Due to the scoring, acomposite panel 10 can be made to curve around a surface if desired, byplacing the side with the mesh against a convex surface or part of asurface, so that the scores will open, as shown in FIG. 5

If a panel 10 of composite material is scored to create smaller scoredsections, the resulting panel can be made to curve around a convexsurface with a smaller radius. Accordingly, a user may desire andspecify scoring having a particular spacing, depending on theapplication. In addition, the scoring of a panel or sheet does not needto be symmetrical, so again, the final shape of the area to bereinforced, if known, can be used to create an optimal scoring patternto result in a high-strength, lightweight final structure.

To reinforce, for example, a flat interior area with a pipe passingthrough it, the area to be reinforced may be coated or sprayed with aresin. For example, the same type of resin the scored composite part ismade of may be used. Using the same type of resin will typically createa very good chemical bond, so that the resulting reinforced structureacts as though it is a single, solid piece. Next, the mesh side 19 ofthe panel 10 may be placed against the surface and the pipe orstructure, and the “scores” of the panel can open wider to allow thepanel 10 to wrap around and generally conform to the pipe (or any suchirregular surface). After a panel 10 is installed in this manner,additional resin or material can be applied (such as sprayed, choppedfiberglass with resin) to fill in the open, scored sections of thepanel, again with the same type of resin from which the panel is made,to ensure strong chemical bonding.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although methods and materialssimilar to or equivalent to those described herein can be used in thepractice or testing of the composition and method to form a compositecore material, suitable methods and materials are described above. Allpublications, patent applications, patents, and other referencesmentioned herein are incorporated by reference in their entirety to theextent allowed by applicable law and regulations. The composition andmethod to form a composite core material may be embodied in otherspecific forms without departing from the spirit or essential attributesthereof, and it is therefore desired that the present embodiment beconsidered in all respects as illustrative and not restrictive. Anyheadings utilized within the description are for convenience only andhave no legal or limiting effect.

What is claimed is:
 1. A composite core material, comprising microsphere discontinuous portions disposed in a continuous encapsulating resin mixture; wherein the microsphere discontinuous portion comprises plastic microspheres, glass microspheres, ceramic microspheres, polyvinyl chloride (PVC) microspheres, acrylic microspheres, and any combinations thereof.
 2. The composite core material of claim 1, wherein the microsphere discontinuous portion comprises hollow or solid microspheres.
 3. The composite core material of claim 1, further comprising a blowing agent.
 4. The composite core material of claim 1, wherein the blowing agent is a chemical or mechanical blowing agent.
 5. The composite core material of claim 1, wherein the encapsulating resin mixture comprises resin selected from the group consisting of polyester resin, vinyl ester resin, fire retardant resin and any combinations thereof.
 6. The composite core material of claim 1, wherein the encapsulating resin mixture comprises a polyester resin.
 7. The composite core material of claim 1, wherein the encapsulating resin mixture comprises a vinyl ester resin.
 8. The composite core material of claim 1, wherein the encapsulating resin mixture comprises a fire retardant resin.
 9. The composite core material of claim 1, wherein the encapsulating resin mixture has a weight percentage of about 90-99%; and wherein the microspheres comprise hollow or solid microspheres having a weight percentage of about 1-10%.
 10. A method of making a composite core material product, comprising: forming a mixture comprising microspheres, an encapsulating prepolymer, and a polymerization catalyst; shaping the mixture into a particular form; and polymerizing the encapsulating prepolymer to form a composite material comprising hollow or solid microsphere discontinuous portions disposed in a continuous encapsulating resin mixture.
 11. The method of claim 10, wherein the hollow or solid microspheres are selected from the group consisting of plastic microspheres, glass microspheres, ceramic microspheres, polyvinyl chloride (PVC) microspheres, acrylic microspheres, and any combinations thereof.
 12. The method of claim 10, wherein the encapsulating prepolymer is selected from the group consisting of a polyester prepolymer, a vinyl ester prepolymer, a fire retardant prepolymer, and any combinations thereof.
 13. The method of claim 10, wherein the encapsulating prepolymer has a weight percentage of about 90-99%; and wherein the microspheres comprise hollow or solid microspheres having a weight percentage of about 1-10%.
 14. The method of claim 13, wherein: shaping the mixture into a particular form step further comprises disposing said mixture onto a mesh assembly positioned on a moving belt to form a sheet comprising said mixture and the mesh assembly; and wherein polymerizing the encapsulating prepolymer further comprises curing the encapsulating prepolymer to form a sheet of composite material having a mesh assembly proximate a first side of the sheet.
 15. The method of claim 14, further comprising scoring the sheet of the composite material into a plurality of reinforcing blocks on a side of the sheet spaced apart from the first side of the sheet.
 16. The method of claim 10, wherein: shaping the mixture into a particular form further comprises disposing said mixture onto a mesh assembly positioned on a moving belt to form a sheet comprising said mixture and the mesh assembly; and wherein polymerizing the encapsulating prepolymer further comprises curing the encapsulating prepolymer to form a sheet of composite material having a mesh assembly proximate a first side of the sheet.
 17. The method of claim 16, further comprising scoring the sheet of the composite material into a plurality of reinforcing blocks on a side of the sheet spaced apart from the first side of the sheet.
 18. The method of claim 10, wherein: shaping the mixture into a particular form further comprises disposing the mixture into a mold with a mesh assembly located inside the mold; and wherein polymerizing the encapsulating prepolymer further comprises curing the encapsulating prepolymer to form a composite material product according to the shape of the mold, the composite material product having a mesh assembly proximate a first surface of the product.
 19. The method of claim 18, further comprising scoring the composite material product into a plurality of reinforcing blocks on a side of the product spaced apart from the mesh assembly.
 20. The method of claim 18, further comprising positioning a second mesh assembly in the mold on a side of the mold spaced apart from the first mesh assembly. 